Hypertherm Mechanized Family Instruction Manual (IM)

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Plasma Arc Cutting System

Instruction Manual 801310 – Revision 4

(200/220/240V, 1-Ph, 50/60 Hz)

MAX20

EN50199 EN60974-1

MAX20

(200/220/240 Volt, 1-Ph, 50/60 Hz)

Instruction Manual

(P/N 801310)

Revision 4 – November 2001

Hypertherm, and MAX are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

800-643-9878 Tel (Technical Service)

800-737-2978 Tel (Customer Service)

Hypertherm Automation, LLC

5 Technology Drive

West Lebanon, NH 03755 USA

603-298-7970 Tel

603-298-7977 Fax

Hypertherm Plasmatechnik, GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd

No. 19 Kaki Bukit Road 2

K.B. Warehouse Complex

Singapore 417847, Republic of Singapore

65 6 841 2489 Tel

65 6 841 2490 Fax

65 6 841 2489 (Technical Service)

Japan

1952-14 Yata-Natsumegi

Mishima City, Shizuoka Pref.

411-0801 Japan

81 0 559 75 7387 Tel

81 0 559 75 7376 Fax

Hypertherm UK, Ltd

9 Berkeley Court, Manor Park

Runcorn, Cheshire, England WA7 1TQ

44 1928 579 074 Tel

44 1928 579 604 Fax

France

15 Impasse des Rosiers

95610 Eragny, France

00 800 3324 9737 Tel

00 800 4973 7329 Fax

Hypertherm S.r.l.

Via Torino 2

20123 Milano, Italia

39 02 725 46 312 Tel

39 02 725 46 400 Fax

39 02 725 46 314 (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9

4704 SE Roosendaal, Nederland

31 165 596908 Tel

31 165 596901 Fax

Technical Service:

00 800 49 73 7843 – toll-free in Europe

31 165 596900 Tel

Hypertherm Brasil Ltda.

Rua Visconde de Santa Isabel, 20 – Sala 611

Vila Isabel, RJ

Brasil CEP 20560-120

55 21 2278 6162 Tel

55 21 2578 0947 Fax

3/27/03

ELECTROMAGNETIC COMPATIBILITY (EMC)

EMC INTRODUCTION

Hypertherm's CE-marked equipment is built in compliance with standard EN50199. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN50199 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference.

This plasma equipment is designed for use only in an industrial environment.

INSTALLATION AND USE

The user is responsible for installing and using the plasma equipment according to the manufacturer's instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

ASSESSMENT OF AREA

Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out.

Earthing of Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship's hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note. The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC TC26 (sec)94 and IEC TC26/108A/CD Arc Welding Equipment Installation and Use.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Cutting equipment must be connected to the mains supply according to the manufacturer's recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure

Maintenance of Cutting Equipment

The cutting equipment must be routinely maintained according to the manufacturer's recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer's instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer's recommendations.

Cutting Cables

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Hypertherm Plasma Systems i

WARRANTY

ii Hypertherm Plasma Systems

9-01

WARNING

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

WARNING

You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.

GENERAL

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of G3 Series power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight prepaid. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty above is

exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty. Distributors/OEMs may offer

different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

PATENT INDEMNITY

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by

Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement, and Hypertherm’s obligation to indemnify shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

LIMITATION OF LIABILITY

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential, indirect, or punitive damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise and even if advised of the possibility of such damages.

LIABILITY CAP

In no event shall Hypertherm’s liability, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

INSURANCE

At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the Products.

NATIONAL AND LOCAL CODES

National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

TRANSFER OF RIGHTS

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty.

MAX20 Instruction Manual iii

Electromagnetic Compatibility (EMC).......................................................................................................................i

Warranty .....................................................................................................................................................................ii

Section 1 SAFETY..................................................................................................................................................1-1

Recognize Safety Information...................................................................................................................................1-2

Follow Safety Instructions.........................................................................................................................................1-2

Cutting Can Cause Fire or Explosion .......................................................................................................................1-2

Electric Shock Can Kill..............................................................................................................................................1-3

Cutting Can Produce Toxic Fumes...........................................................................................................................1-3

A Plasma Arc Can Cause Injury and Burns..............................................................................................................1-4

Arc Rays Can Burn Eyes and Skin ...........................................................................................................................1-4

Grounding Safety......................................................................................................................................................1-4

Compressed Gas Equipment Safety ........................................................................................................................1-5

Gas Cylinders Can Explode If Damaged ..................................................................................................................1-5

Noise Can Damage Hearing.....................................................................................................................................1-5

Pacemaker and Hearing Aid Operation ....................................................................................................................1-5

A Plasma Arc Can Damage Frozen Pipes................................................................................................................1-5

Additional Safety Information....................................................................................................................................1-5

Warning Label...........................................................................................................................................................1-6

Section 1a SÉCURITÉ........................................................................................................................................1a-1

Identifier les consignes de sécurité.........................................................................................................................1a-2

Suivre les instructions de sécurité ..........................................................................................................................1a-2

Le coupage peut provoquer un incendie ou une explosion ....................................................................................1a-2

Les chocs électriques peuvent être fatals...............................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques....................................................................................................1a-3

L'arc plasma peut provoquer des blessures ou des brûlures .................................................................................1a-4

Mise à la masse et à la terre...................................................................................................................................1a-4

Les rayons de l'arc peuvent brûler les yeux et la peau...........................................................................................1a-4

Sécurité des bouteilles de gaz comprimé ...............................................................................................................1a-5

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages .............................................................1a-5

Le bruit peut provoquer des problèmes auditifs......................................................................................................1a-5

Pacemakers et prothéses auditives........................................................................................................................1a-5

Étiquette de sécurité ...............................................................................................................................................1a-6

Section 2 SPECIFICATIONS................................................................................................................................2-1

General .....................................................................................................................................................................2-2

Product Specifications ..............................................................................................................................................2-3

MAX20 CE Power Supply ................................................................................................................................2-3

PAC110 Torch..................................................................................................................................................2-3

IEC Symbols Used....................................................................................................................................................2-4

Section 3 SETUP..................................................................................................................................................3-1

Upon Receipt ............................................................................................................................................................3-2

Primary Connection ..................................................................................................................................................3-2

Line Voltage and Frequency Selection .....................................................................................................................3-5

Grounding .................................................................................................................................................................3-6

Air Supply .................................................................................................................................................................3-6

TABLE OF CONTENTS

iv MAX20 Instruction Manual

Section 4 OPERATION ........................................................................................................................................4-1

Front Panel Controls.................................................................................................................................................4-2

Operating Instructions...............................................................................................................................................4-3

Operating Tips ..........................................................................................................................................................4-4

Changing Consumable Parts ...........................................................................................................................4-4

Adjusting Output Power ...................................................................................................................................4-5

Cutting..............................................................................................................................................................4-6

Piercing ............................................................................................................................................................4-7

Common Cutting Faults ...................................................................................................................................4-8

Duty Cycle........................................................................................................................................................4-8

Gas Pressure ...................................................................................................................................................4-9

Torch Heat .......................................................................................................................................................4-9

Claims and Technical Questions ............................................................................................................................4-10

Section 5 MAINTENANCE ...................................................................................................................................5-1

Troubleshooting ........................................................................................................................................................5-2

Problems: Causes and Solutions .....................................................................................................................5-3

System Illustrations ..........................................................................................................................................5-7

Torch Repair .............................................................................................................................................................5-9

Repair Kit & Customer-Supplied Tools ............................................................................................................5-9

Remove the Defective Torch............................................................................................................................5-9

Install the New Torch .......................................................................................................................................5-9

Section 6 PARTS LIST.........................................................................................................................................6-1

PAC110 Torch Assembly and Leads........................................................................................................................6-2

MAX20 CE Power Supply.........................................................................................................................................6-3

System Descriptions ........................................................................................................................................6-3

MAX20 CE Parts .............................................................................................................................................6-3

Section 7 WIRING DIAGRAMS............................................................................................................................7-1

Wiring Diagram .........................................................................................................................................................7-3

Hypertherm Plasma Systems 1-1

Section 1

SAFETY

In this section:

Recognize Safety Information.........................................................................................................................1-2

Follow Safety Instructions ...............................................................................................................................1-2

Cutting Can Cause Fire or Explosion..............................................................................................................1-2

Electric Shock Can Kill....................................................................................................................................1-3

Cutting Can Produce Toxic Fumes..................................................................................................................1-3

A Plasma Arc Can Cause Injury and Burns.....................................................................................................1-4

Arc Rays Can Burn Eyes and Skin .................................................................................................................1-4

Grounding Safety ............................................................................................................................................1-4

Compressed Gas Equipment Safety...............................................................................................................1-5

Gas Cylinders Can Explode If Damaged ........................................................................................................1-5

Noise Can Damage Hearing ...........................................................................................................................1-5

Pacemaker and Hearing Aid Operation...........................................................................................................1-5

A Plasma Arc Can Damage Frozen Pipes ......................................................................................................1-5

Additional Safety Information ..........................................................................................................................1-5

Warning Label.................................................................................................................................................1-6

SAFETY

1-2 Hypertherm Plasma Systems

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SAFETY

RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard.

FOLLOW SAFETY INSTRUCTIONS

Read carefully all safety messages in this manual and safety labels on your machine.

• Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.

• Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction.

• Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life.

DANGER WARNING CAUTION

A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serious hazards.

• DANGER and WARNING safety labels are located on your machine near specific hazards.

• WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly.

• CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly.

Fire Prevention

• Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby.

• Remove all flammables within 35 feet (10 m) of the cutting area.

• Quench hot metal or allow it to cool before handling or before letting it touch combustible materials.

• Never cut containers with potentially flammable materials inside – they must be emptied and properly cleaned first.

• Ventilate potentially flammable atmospheres before cutting.

• When cutting with oxygen as the plasma gas, an exhaust ventilation system is required.

Explosion Prevention

• Do not use the plasma system if explosive dust or vapors may be present.

• Do not cut pressurized cylinders, pipes, or any closed container.

• Do not cut containers that have held combustible materials.

CUTTING CAN CAUSE FIRE OR EXPLOSION

WARNING

Explosion Hazard

Argon-Hydrogen and Methane

Hydrogen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.

WARNING

Hydrogen Detonation with Aluminum Cutting

• When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations.

• Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Refer to the Appendix section of this manual for aeration manifold details.

Touching live electrical parts can cause a fatal shock or severe burn.

• Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

• Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.

Electric Shock Prevention All Hypertherm plasma systems use high voltage

in the cutting process (200 to 400 VDC are common). Take the following precautions when operating this system:

• Wear insulated gloves and boots, and keep your body and clothing dry.

• Do not stand, sit or lie on – or touch – any wet surface when using the plasma system.

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

• Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.

• When using a water table, be sure that it is correctly connected to earth ground.

ELECTRIC SHOCK CAN KILL

• Install and ground this equipment according to the instruction manual and in accordance with national and local codes.

• Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

• Inspect and replace any worn or damaged torch leads.

• Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

• Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.

• Never bypass or shortcut the safety interlocks.

• Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.

• Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.

• When making input connections, attach proper grounding conductor first.

• Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.

• Keep the cutting area well ventilated or use an approved air-supplied respirator.

• Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.

• Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or

CUTTING CAN PRODUCE TOXIC FUMES

beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.

• Never cut containers with potentially toxic materials inside – they must be emptied and properly cleaned first.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.

Hypertherm Plasma Systems 1-3

8-99

SAFETY

1-4 Hypertherm Plasma Systems

4-99

SAFETY

Instant-On Torches

Plasma arc comes on immediately when the torch switch is activated.

A PLASMAARC CAN CAUSE INJURYAND BURNS

The plasma arc will cut quickly through gloves and skin.

• Keep away from the torch tip.

• Do not hold metal near the cutting path.

• Never point the torch toward yourself or others.

Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

• Use eye protection in accordance with applicable national or local codes.

• Wear eye protection (safety glasses or goggles with side shields, or a welding helmet) with appropriate lens shading to protect your eyes from the arc’s ultraviolet and infrared rays.

Lens Shade

Arc Current AWS (USA) ISO 4850

Up to 100 A No. 8 No. 11 100-200 A No. 10 No. 11-12 200-400 A No. 12 No. 13 Over 400 A No. 14 No. 14

ARC RAYS CAN BURN EYES AND SKIN

Skin Protection Wear protective clothing to protect

against burns caused by ultraviolet light, sparks and hot metal.

• Gauntlet gloves, safety shoes and hat.

• Flame-retardant clothing to cover all exposed areas.

• Cuffless trousers to prevent entry of sparks and slag.

• Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

• Paint walls and other surfaces with dark colors to reduce reflection.

• Use protective screens or barriers to protect others from flash and glare.

• Warn others not to watch the arc. Use placards or signs.

Work Cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete.

Work Table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes.

GROUNDING SAFETY

Input Power

• Be sure to connect the power cord ground wire to the ground in the disconnect box.

• If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.

• Place the power cord's ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

• Tighten all electrical connections to avoid excessive heating.

SAFETY

Hypertherm Plasma Systems 1-5

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SAFETY

• Never lubricate cylinder valves or regulators with oil or grease.

• Use only correct gas cylinders, regulators, hoses and fittings designed for the specific application.

• Maintain all compressed gas equipment and associated parts in good condition.

• Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national or local codes.

GAS CYLINDERS CAN EXPLODE IF DAMAGED

COMPRESSED GAS EQUIPMENT SAFETY

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

• Handle and use compressed gas cylinders in accordance with applicable national or local codes.

• Never use a cylinder that is not upright and secured in place.

• Keep the protective cap in place over valve except when the cylinder is in use or connected for use.

• Never allow electrical contact between the plasma arc and a cylinder.

• Never expose cylinders to excessive heat, sparks, slag or open flame.

• Never use a hammer, wrench or other tool to open a stuck cylinder valve.

Prolonged exposure to noise from cutting or gouging can damage hearing.

• Use approved ear protection when using plasma system.

• Warn others nearby about the noise hazard.

NOISE CAN DAMAGE HEARING

Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.

To reduce magnetic field hazards:

• Keep both the work cable and the torch lead to one side, away from your body.

• Route the torch leads as close as possible to the work cable.

• Do not wrap or drape the torch lead or work cable around your body.

• Keep as far away from the power supply as possible.

P ACEMAKER AND HEARING AID OPERATION

ADDITIONAL SAFETY INFORMATION

1. ANSI Standard Z49.1, Safety in Welding and Cutting, American Welding Society, 550 LeJeune Road P.O. Box 351020, Miami, FL 33135

2. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding Processes, American National Standards Institute 1430 Broadway, New York, NY 10018

3. ANSI Standard Z87.1, Safe Practices for Occupation and Educational Eye and Face Protection, American National Standards Institute, 1430 Broadway, New York, NY 10018

4. AWS F4.1, Recommended Safe Practices for the Preparation for

Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, American Welding Society

550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

5. AWS F5.2, Recommended Safe Practices for Plasma Arc Cutting, American Welding Society 550 LeJeune Road, P.O. Box 351040, Miami, FL 33135

6. CGA Pamphlet P-1, Safe Handling of Compressed Gases in Cylinders, Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202

7. CSA Standard W117.2, Code for Safety in Welding and Cutting, Canadian Standards Association Standard Sales 178 Rexdale Boulevard, Rexdale, Ontario M9W 1R3, Canada

8. NFPA Standard 51B, Cutting and Welding Processes, National Fire Protection Association 470 Atlantic Avenue, Boston, MA 02210

9. NFPA Standard 70–1978, National Electrical Code, National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210

10. OSHA, Safety and Health Standards, 29FR 1910

U.S. Government Printing Office, Washington, D.C. 20402

A PLASMAARC CAN DAMAGE FROZEN PIPES

Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

SAFETY

1-6 Hypertherm Plasma Systems

8-99

SAFETY

WARNING LABEL

This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label.

1. Cutting sparks can cause explosion or fire.

1.1 Keep flammables away from cutting.

1.2 Keep a fire extinguisher nearby, and have a watchperson ready to use it.

1.3 Do not cut on any closed containers.

2. The plasma arc can cause injury and burns.

2.1 Turn off power before disassembling torch.

2.2 Do not hold the material near cutting path.

2.3 Wear complete body protection.

3. Electric shock from torch or wiring can kill. Protect yourself from electric shock.

3.1 Wear insulating gloves. Do not wear wet or damaged gloves.

3.2 Insulate yourself from work and ground.

3.3 Disconnect input plug or power before working on machine.

4. Breathing cutting fumes can be hazardous to your health.

4.1 Keep your head out of the fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Use ventilating fan to remove the fumes.

5. Arc rays can burn eyes and injure skin.

5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

6. Become trained and read the instructions before working on the machine or cutting.

7. Do not remove or paint over (cover) warning labels.

Hypertherm Systèmes plasma 1a-1

2/12/01

Section 1

SÉCURITÉ

Dans cette section :

Identifier les consignes de sécurité.................................................................................................................1-2

Suivre les instructions de sécurité...................................................................................................................1-2

Danger Avertissement Précaution.................................................................................................................1-2

Le coupage peut provoquer un incendie ou une explosion.............................................................................1-2

Prévention des incendies, Prévention des explosions ...........................................................................1-2

Risque d’explosion argon-hydrogène et méthane..................................................................................1-2

Détonation de l’hydrogène lors du coupage de l’aluminium...................................................................1-2

Les chocs électriques peuvent être fatals.......................................................................................................1-3

Prévention des chocs électriques...........................................................................................................1-3

Le coupage peut produire des vapeurs toxiques ............................................................................................1-3

L’arc plasma peut provoquer des blessures ou des brûlures..........................................................................1-4

Torches à allumage instantané...............................................................................................................1-4

Les rayons de l’arc peuvent brûler les yeux et la peau...................................................................................1-4

Protection des yeux, Protection de la peau, Zone de coupage ............................................................1-4

Mise à la masse et à la terre...........................................................................................................................1-4

Câble de retour, Table de travail, Alimentation .......................................................................................1-4

Sécurité des bouteilles de gaz comprimé .......................................................................................................1-5

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages......................................................1-5

Le bruit peut provoquer des problèmes auditifs..............................................................................................1-5

Pacemakers et prothèses auditives ................................................................................................................1-5

Un arc plasma peut endommager les tuyaux gelés........................................................................................1-5

Étiquette de sécurité .......................................................................................................................................1-6

SÉCURITÉ

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IDENTIFIER LES CONSIGNES DE SÉCURITÉ

Les symboles indiqués dans cette section sont utilisés pour identifier les risques éventuels. Si vous trouvez un symbole de sécurité, que ce soit dans ce manuel ou sur l’équipement, soyez conscient des risques de blessures et suivez les instructions correspondantes afin d’éviter ces risques.

SUIVRE LES INSTRUCTIONS DE SÉCURITÉ

Lire attentivement toutes les consignes de sécurité dans le présent manuel et sur les étiquettes de sécurité se trouvant sur la machine.

• Les étiquettes de sécurité doivent rester lisibles. Remplacer immédiatement les étiquettes manquantes ou abîmées.

• Apprendre à faire fonctionner la machine et à utiliser correctement les commandes. Ne laisser personne utiliser la machine sans connaître son fonctionnement.

• Garder la machine en bon état. Des modifications non autorisées sur la machine peuvent engendrer des problèmes de sécurité et raccourcir la durée d’utilisation de l’équipement.

DANGER AVERTISSEMENT PRÉCAUTION

Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.

• Les étiquettes de sécurité DANGER et AVERTISSEMENT sont situées sur la machine pour signaler certains dangers spécifiques.

• Les messages d’AVERTISSEMENT précèdent les instructions d’utilisation expliquées dans ce manuel et signalent les risques de blessures ou de mort au cas où ces instructions ne seraient pas suivies correctement.

• Les messages de PRÉCAUTION précèdent les instructions d’utilisation contenues dans ce manuel et signalent que le matériel risque d’être endommagé si les instructions ne sont pas suivies correctement.

Prévention des incendies

• Avant de commencer, s’assurer que la zone de coupage ne présente aucun danger. Conserver un extincteur à proximité.

• Éloigner toute matière inflammable à une distance d’au moins 10 m du poste de coupage.

• Tremper le métal chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des matériaux combustibles.

• Ne jamais couper des récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.

• Aérer toute atmosphère potentiellement inflammable avant d’utiliser un système plasma.

• Lors de l’utilisation d’oxygène comme gaz plasma, un système de ventilation par aspiration est nécessaire.

Prévention des explosions

• Ne pas couper en présence de poussière ou de vapeurs.

• Ne pas couper de bouteilles, de tuyaux ou autres récipients fermés et pressurisés.

• Ne pas couper de récipients contenant des matières combustibles.

LE COUPAGE PEUT PROVOQUER UN INCENDIE

OU UNE EXPLOSION

AVERTISSEMENT

Risque d’explosion

argon-hydrogène et méthane

L’hydrogène et le méthane sont des gaz inflammables et potentiellement explosifs. Conserver à l’écart de toute flamme les bouteilles et tuyaux contenant des mélanges à base d’hydrogène ou de méthane. Maintenir toute flamme et étincelle à l’écart de la torche lors de l’utilisation d’un plasma d’argon-hydrogène ou de méthane.

AVERTISSEMENT

Détonation de l’hydrogène lors du

coupage de l’aluminium

• Lors du coupage de l’aluminium sous l’eau, ou si l’eau touche la partie inférieure de la pièce d’aluminium, de l’hydrogène libre peut s’accumuler sous la pièce à couper et détonner lors du coupage plasma.

• Installer un collecteur d’aération au fond de la table à eau afin d’éliminer les risques de détonation de l’hydrogène. Se référer à l’annexe du manuel pour plus de renseignements sur les collecteurs d’aération.

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Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves.

• La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique.

• Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.

Prévention des chocs électriques

Tous les systèmes plasma Hypertherm utilisent des hautes tensions pour le coupage (souvent de 200 à 400 V). On doit prendre les précautions suivantes quand on utilise le système plasma :

• Porter des bottes et des gants isolants et garder le corps et les vêtements au sec.

• Ne pas se tenir, s’asseoir ou se coucher sur une surface mouillée, ni la toucher quand on utilise le système plasma.

• S’isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour éviter tout contact physique avec le travail ou le sol. S’il s’avère nécessaire de travailler dans ou près d’un endroit humide, procéder avec une extrême prudence.

• Installer un sectionneur avec fusibles appropriés, à proximité de la source de courant. Ce dispositif permet à l’opérateur d’arrêter rapidement la source de courant en cas d’urgence.

• En cas d’utilisation d’une table à eau, s’assurer que cette dernière est correctement mise à la terre.

LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS

• Installer et mettre à la terre l’équipement selon les instructions du présent manuel et conformément aux codes électriques locaux et nationaux.

• Inspecter fréquemment le cordon d’alimentation primaire pour s’assurer qu’il n’est ni endommagé, ni fendu. Remplacer immédiatement un cordon endommagé. Un câble dénudé peut tuer.

• Inspecter et remplacer les câbles de la torche qui sont usés ou endommagés.

• Ne pas saisir la pièce à couper ni les chutes lors du coupage. Laisser la pièce à couper en place ou sur la table de travail, le câble de retour connecté lors du coupage.

• Avant de vérifier, de nettoyer ou de remplacer les pièces de la torche, couper l’alimentation ou débrancher la prise de courant.

• Ne jamais contourner ou court-circuiter les verrouillages de sécurité.

• Avant d’enlever le capot du système ou de la source de courant, couper l’alimentation électrique. Attendre en

suite

5 minutes pour que les condensateurs se déchargent.

• Ne jamais faire fonctionner le système plasma sans que les capots de la source de courant ne soient en place. Les raccords exposés de la source de courant sont extrêmement dangereux.

• Lors de l’installation des connexions, attacher tout d’abord la prise de terre appropriée.

• Chaque système plasma Hypertherm est conçu pour être utilisé uniquement avec des torches Hypertherm spécifiques. Ne pas utiliser des torches inappropriées qui pourraient surchauffer et présenter des risques pour la sécurité.

Le coupage peut produire des vapeurs et des gaz toxiques qui réduisent le niveau d’oxygène dans l’air et peuvent provoquer des blessures, voire la mort.

• Conserver le poste de coupage bien aéré ou utiliser un masque respiratoire homologué.

• Ne pas procéder au coupage près d’endroits où s’effectuent le dégraissage, le nettoyage ou la vaporisation. Certains solvants chlorés se décomposent sous l’effet des rayons ultraviolets et forment du phosgène.

• Ne pas couper des métaux peints ou contenant des matières toxiques comme le zinc (galvanisé), le plomb, le cadmium ou le béryllium, à moins que la zone de travail

LE COUPAGE PEUT PRODUIRE DES VAPEURS TOXIQUES

soit très bien ventilée et que l’opérateur porte un masque respiratoire. Les revêtements et métaux contenant ces matières peuvent produire des vapeurs toxiques lors du coupage.

• Ne jamais couper de récipients pouvant contenir des matières inflammables avant de les avoir vidés et nettoyés correctement.

• Quand on utilise ce produit pour le soudage ou le coupage, il dégage des fumées et des gaz qui contiennent des produits chimiques qui, selon l’État de Californie, provoquent des anomalies congénitales et, dans certains cas, le cancer.

SÉCURITÉ

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Torches à allumage instantané

L’arc plasma s’allume immédiatement après que la torche soit mise en marche.

L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES

L’arc plasma coupe facilement les gants et la peau.

• Rester éloigné de l’extrémité de la torche.

• Ne pas tenir de métal près de la trajectoire de coupe.

• Ne jamais pointer la torche vers soi ou d’autres personnes.

Protection des yeux Les rayons de l’arc plasma produisent de puissants rayons visibles ou invisibles (ultraviolets et infrarouges) qui peuvent brûler les yeux et la peau.

• Utiliser des lunettes de sécurité conformément aux codes locaux ou nationaux en vigueur.

• Porter des lunettes de protection (lunettes ou masque muni d’écrans latéraux ou encore masque de soudure) avec des verres teintés appropriés pour protéger les yeux des rayons ultraviolets et infrarouges de l’arc.

Puissance des verres teintés

Courant de l’arc AWS (É.-U.) ISO 4850

Jusqu’à 100 A No8N

11 100-200 A No10 No11-12 200-400 A No12 No13 Plus de 400 A No14 No14

Protection de la peau Porter des vêtements de sécurité pour se protéger contre les brûlures que peuvent causer les rayons ultraviolets, les étincelles et le métal brûlant :

LES RAYONS DE L’ARC PEUVENT BRÛLER LES YEUX ET LA PEAU

• Gants à crispin, chaussures et casque de sécurité.

• Vêtements ignifuges couvrant toutes les parties exposées du corps.

• Pantalon sans revers pour éviter que des étincelles ou des scories puissent s’y loger.

• Avant le coupage, retirer de ses poches tout objet combustible comme les briquets au butane ou les allumettes.

Zone de coupage Préparer la zone de coupage afin de réduire la réverbération et la transmission de la lumière ultraviolette :

• Peindre les murs et autres surfaces de couleur sombre pour réduire la réflexion de la lumière.

• Utiliser des écrans et autres dispositifs de protection afin de protéger les autres personnes de la lumière et de la réverbération.

• Prévenir les autres personnes de ne pas regarder l’arc. Utiliser des affiches ou des panneaux.

Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher.

Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.

MISE À LA MASSE ET À LA TERRE

Alimentation

• S’assurer que le fil de terre du cordon d’alimentation est connecté à la terre dans le coffret du sectionneur.

• S’il est nécessaire de brancher le cordon d’alimentation à la source de courant lors de l’installation du système, s’assurer que le fil de terre est correctement branché.

• Placer tout d’abord le fil de terre du cordon d’alimentation sur le plot de mise à la terre puis placer les autres fils de terre par-dessus. Bien serrer l’écrou de retenue.

• S’assurer que toutes les connexions sont bien serrées pour éviter la surchauffe.

SÉCURITÉ

Hypertherm Systèmes plasma 1a-5

2/12/01

• Ne jamais lubrifier les robinets des bouteilles ou les régulateurs avec de l’huile ou de la graisse.

• Utiliser uniquement les bouteilles, régulateurs, tuyaux et accessoires appropriés et conçus pour chaque application spécifique.

• Entretenir l’équipement et les pièces d’équipement à gaz comprimé afin de les garder en bon état.

• Étiqueter et coder avec des couleurs tous les tuyaux de gaz afin d’identifier le type de gaz contenu dans chaque tuyau. Se référer aux codes locaux ou nationaux en vigueur.

LES BOUTEILLES DE GAZ COMPRIMÉ PEUVENT EXPLOSER EN CAS DE DOMMAGES

SÉCURITÉ DES BOUTEILLES DE GAZ COMPRIMÉ

Les bouteilles de gaz contiennent du gaz à haute pression. Si une bouteille est endommagée, elle peut exploser.

• Manipuler et utiliser les bouteilles de gaz comprimé conformément aux codes locaux ou nationaux.

• Ne jamais utiliser une bouteille qui n’est pas placée à la verticale et bien assujettie.

• Le capuchon de protection doit être placé sur le robinet sauf si la bouteille est en cours d’utilisation ou connectée pour utilisation.

• Éviter à tout prix le contact électrique entre l’arc plasma et une bouteille.

• Ne jamais exposer des bouteilles à une chaleur excessive, aux étincelles, aux scories ou aux flammes nues.

• Ne jamais utiliser des marteaux, des clés ou d’autres outils pour débloquer le robinet des bouteilles.

Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs.

• Utiliser un casque de protection homologué lors de l’utilisation du système plasma.

• Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit.

LE BRUIT PEUT PROVOQUER DES

PROBLÈMES AUDITIFS

Les champs magnétiques produits par les courants à haute tension peuvent affecter le fonctionnement des prothèses auditives et des pacemakers. Les personnes portant ce type d’appareil doivent consulter un médecin avant de s’approcher d’un lieu où s’effectue le coupage ou le gougeage plasma.

Pour réduire les risques associés aux champs magnétiques :

• Garder loin de soi et du même côté du corps le câble de retour et le faisceau de la torche.

• Faire passer le faisceau de la torche le plus près possible du câble de retour.

• Ne pas s’enrouler le faisceau de la torche ou le câble de retour autour du corps.

• Se tenir le plus loin possible de la source de courant.

PACEMAKERS ET PROTHÈSES AUDITIVES

Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma.

UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS

SÉCURITÉ

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Étiquette de sécurité

Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images.

1. Les étincelles produites par le coupage peuvent provoquer une explosion ou un incendie.

1.1 Pendant le coupage, éloigner toute matière inflammable.

1.2 Conserver un extincteur à proximité et s’assurer qu’une personne soit prête à l’utiliser.

1.3 Ne jamais couper de récipients fermés.

2. L’arc plasma peut provoquer des blessures et des brûlures.

2.1 Couper l’alimentation avant de démonter la torche.

2.2 Ne pas tenir la surface à couper près de la trajectoire de coupe.

2.3 Porter des vêtements de protection couvrant tout le corps.

3. Un choc électrique causé par la torche ou les câbles peut être fatal. Se protéger contre les risques de chocs électriques.

3.1 Porter des gants isolants. Ne pas porter de gants mouillés ou abîmés.

3.2 S’isoler de la surface de travail et du sol.

3.3 Débrancher la prise ou la source de courant avant de manipuler l’équipement.

4. L’inhalation des vapeurs produites par le coupage peut être dangereuse pour la santé.

4.1 Garder le visage à l’écart des vapeurs.

4.2 Utiliser un système de ventilation par aspiration ou d’échappement localisé pour dissiper les vapeurs.

4.3 Utiliser un ventilateur pour dissiper les vapeurs.

5. Les rayons de l’arc peuvent brûler les yeux et provoquer des lésions de la peau.

5.1 Porter un casque et des lunettes de sécurité. Se protéger les oreilles et porter une chemise dont le col peut être déboutonné. Porter un casque de soudure dont la protection filtrante est suffisante. Porter des vêtements protecteurs couvrant la totalité du corps.

6. Se former à la technique du coupage et lire les instructions avant de manipuler l’équipement ou de procéder au coupage.

7. Ne pas retirer ou peindre (recouvrir) les étiquettes de sécurité.

MAX20 Instruction Manual 2-1

Section 2

SPECIFICATIONS

In this section:

General .....................................................................................................................................................................2-2

Product Specifications ..............................................................................................................................................2-3

MAX20 CE Power Supply ................................................................................................................................2-3

PAC110 Torch...................................................................................................................................................2-3

IEC Symbols Used....................................................................................................................................................2-4

2-2 MAX20 Instruction Manual

SPECIFICATIONS

General

• Hypertherm’s MAX20 CE air plasma cutting system is designed for hand cutting of most metals up to 6 mm

(1/4 inch) in thickness.

• The MAX20 provides continuously variable current output from 10 to 20 amps to provide excellent cutting performance on all thicknesses within its range.

• The MAX20 power supply uses 200/220/240-volt, single-phase, 50/60 hertz power and incorporates advanced transistor technology. It offers the following benefits:

– It weighs only 20 kg (44 pounds), offering maximum portability.

– The pilot arc ignition pierces coated, painted or rusted metals.

– The solid-state design allows a steady cutting arc between the torch and the workpiece.

– The transistorized design performs best while lightly dragging the torch nozzle on the workpiece. This makes

the torch extremely easy to use.

– The continuous pilot arc makes it easy to cut grate material or other perforated metals. The pilot arc transfers

to the workpiece when the torch is within 3 mm (1/8 inch) of the cutting surface.

– The nearly ripple-free output provides a smooth cutting arc, ensuring high-quality cuts across a wide variety of

materials and thicknesses.

• The MAX20 uses compressed air as the plasma gas. A cylinder of compressed air or an air compressor may be used. The air supply must be free of moisture, oil or other contaminants. An air pressure regulator and air filter are provided. The air pressure regulator is preset to deliver the correct air flow and pressure.

• The variable amperage output (OUTPUT POWER) potentiometer mounted on the front panel adjusts the cutting current of the torch and varies the AC line draw of the system to conform with the fuse size at the primary power line.

MAX20 Instruction Manual 2-3

SPECIFICATIONS

Product Specifications

MAX20 CE Power Supply

The MAX20 CE (070049) is a constant current chopper power supply providing continuously variable amperage from 10 amps to 20 amps. It conforms to the following specifications:

Rated OCV (U

) ...................................................240 VDC at rated input voltage

Output Current (I2)................................................10 amps minimum to 20 amps maximum

Output Voltage (U2) .............................................84 VDC @ 10 amps; 88 VDC @ 20 amps

Duty Cycle Rating (X) ..........................................25% duty cycle (20 amps, 88 VDC);

100% duty cycle 10 amps.)

Input Voltage (V1).................................................200-220-240V, 1PH, 50/60 Hz, jumper selectable

Input Current (I1) ..................................................13.0 amps @ 1.8 kw out (200-volt input)

11.8 amps @ 1.8 kw out (220-volt input)

10.8 amps @ 1.8 kw out (240-volt input)

Dimensions

Width ....................................................................200 mm (8 inches)

Height...................................................................298 mm (11.75 inches)

Length ..................................................................432 mm (17 inches)

Weight ..................................................................20 kg (44 U.S. pounds)

Gas Supply

Type .....................................................................Air

Quality ..................................................................Clean, Dry, Oil-Free

Air Flow ................................................................127 liters/minute (4.5 scfm)

Air Pressure Setting .............................................4.1 bar (60 psi) for 4.5 meter (15-foot) lead set

4.5 bar (65 psi) for 7.5 meter (25-foot) lead set

Air Requirements .................................................4.8-8.6 bar (70-125 psi)

PAC110 Torch

The PAC110 torch conforms to the following specifications:

Maximum cutting thickness range........................ Up to 6 mm (1/4 inch)

Maximum current at 50% duty cycle ....................20 Amps

Maximum current at 100% duty cycle ..................10 Amps

Gas Flow ..............................................................127 liters/minute (4.5 scfm)

Weight ..................................................................1.4 kg (3 U.S. pounds)

2-4 MAX20 Instruction Manual

SPECIFICATIONS

IEC Symbols Used

Direct Current (DC).

Alternating current (AC).

Plasma cutting torch.

AC input power connection.

The terminal for the external protective (earthed) conductor.

A chopper-based power source.

Anode (+) work clamp.

Temperature switch.

Pressure switch.

Plasma torch in the TEST position (cooling and cutting gas exiting nozzle).

The power is on.

The power is off.

Volt/amp curve.

MAX20 Instruction Manual 3-1

Section 3

SETUP

In this section:

Upon Receipt ............................................................................................................................................................3-2

Primary Connection ..................................................................................................................................................3-2

Line Voltage and Frequency Selection .....................................................................................................................3-5

Grounding .................................................................................................................................................................3-6

Air Supply .................................................................................................................................................................3-6

3-2 MAX20 Instruction Manual

SETUP

Upon Receipt

1. Remove the unit and save the carton. The carton is reusable and provides an impact-resistant box for transporting or storing the unit.

The carton should include:

• MAX20 CE Power Supply

• PAC110 Torch and Leads 4.5 meter (15 ft.) or 7.5 meter (25 ft.)

• Spare Parts Kit

• Instruction Manual

2. Verify that all components are present. Alert your distributor if any parts are missing.

3. Inspect the power supply for any physical damage that may have occurred during shipping. If there is evidence of damage, see the Claims section for instructions.

Before operating the MAX20, read the Safety and Operation sections of this manual.

Primary Connections

To make or change the primary (line) power cord connection:

1. Use rugged line cordage certified by your local or national electrical codes and sized for 16-amp service. For example, in Europe use IEC “harmonized” line cordage sized at 1.5mm

such as HO5VVF3G.150 (vinyl cordage) or H05RRF3G1.50 (rubber cordage). In North America, use 3-conductor UL/CSA certified cordage for rugged service such as Belden #19354 (type SJT-3, 300 V-60°C, 14 AWG–IEC), or Belden #8479 (type SJ-3, 300 V-60°C, 14 AWG). The International and North American color codes are shown below:

2. If the unit has a cord attached, unplug the unit and move the I/O switch to the O (off) position.

Conductors North American International

Line Black Brown Neutral White Blue Ground Green Green/yellow

MAX20 Instruction Manual 3-3

SETUP

3. Wait five minutes to allow the capacitor to discharge. Remove the cover.

4. Loosen the cable grip with a wrench and remove the old cord.

5. Carefully strip back the outer jacket of the new cord 5 cm (2 inches) and strip back the individual wires 10 mm (3/8 inch).

6. For best results, crimp wire-tip ferrules onto the bare wires. Select the correct ferrule according to the following table. Otherwise, twist the bare copper wires of each conductor into a tight bundle.

14 AWG (1.95mm2)-N. American 15mm2-International

Ferrule H2.5/15 (blue cap, 15 mm long) H1.5/14 (red cap, 14 mm long)

7. Feed the cord through the cable grip, insert twisted or ferruled wires to the terminal block (1TB) and tighten the retaining screws with a screwdriver as follows:

Wire Terminal

Brown (black) ~ Blue (white) ~N. Green/yellow (green)

WARNING

The aluminum heatsink (the U-shaped piece of aluminum) is electrically live when the plasma is on. In case of an electronic failure of the chopper circuit, the heatsink may be live when the power is on.

SHOCK HAZARD: The large electrolytic capacitor (blue-cased cylinder located behind the front panel) stores large amounts of energy in the form of electric voltage. Even if the power is off, dangerous voltages exist at the capacitor terminals, on the PC board, and on certain areas of the PC board. Discharge time to 40 volts is 90 seconds. Never discharge the capacitor with a screwdriver or other implement…explosion, property damage and/or personal injury will result. Wait at least five minutes after turning the power supply off before touching the PC board or the capacitor.

See Figure 3-1. In situations where there is no neutral conductor, either phase may be connected to the terminal marked ~N.

3-4 MAX20 Instruction Manual

SETUP

8. Use a wrench to tighten the strain relief. The IEC cord should be able to withstand a 60-newton (30 lb. force) pull without movement of the cord. The North American cord should be able to withstand a 220-newton (50 lb. force) pull without movement of the cord.

9. If necessary, attach a plug (16-amp) which is certified by your local or national electric code. Follow the manufacturer's instructions.

10. Replace the cover and plug the unit in.

Figure 3-1 Primary Connections

International

Brown (Brun)

Blue (Bleu)

Yellow (Jaune)

North American

Black (Noir)

White (Blanc)

Green (Vert)

MAX20 Instruction Manual 3-5

SETUP

Line Voltage and Frequency Selection

Select the correct primary line voltage (U1) and frequency (Hz) by moving the “link” wires at the voltage/frequency selection terminal block as follows:

1. Move the I/O switch to the O (off) position. Unplug the unit.

2. Wait five minutes to allow the capacitor to discharge. Remove the cover.

3. Use a screwdriver to remove the cover plate over the terminal block (2TB).

4. Use a screwdriver to move the voltage (U1) wire to the position indicating the primary line voltage. See Figure 3-2.

5. Use a screwdriver to move the frequency (Hz) link to the position indicating the primary line frequency.

6. Replace the link cover plate.

7. Replace the power supply cover and plug the unit back in.

When using the unit in the shop, use the 200, 220 or 240-volt incoming line in accordance with the following schedule:

Fuse Size Duty Cycle

16 Amps Operates within duty cycle rating at full output. 10 Amps Operates at 60% duty cycle at 13 amps.

Operates at 100% duty cycle at 10 amps.

WARNING

3-6 MAX20 Instruction Manual

SETUP

When operating in the field, check the fuse or circuit breaker size on the incoming line before cutting and adjust the system accordingly. If an extension cord is necessary, use one that is properly rated. Reducing the current enables you to cut with a longer extension cord.

For safety and performance, always minimize the length of the extension cord.

Grounding

The power supply must be properly grounded through the power cable according to your local electric power company requirements. The 200/220/240 VAC MAX20 cabinet is electrically conductive and can present a shock hazard if it is not properly grounded through the wall outlet. The service must be of the 3-wire type with a green/yellow wire protective “Earth Ground.” It must comply with local electrical requirements. See Grounding in the Safety section.

DO NOT USE A 2-WIRE SERVICE!

The work clamp must make good metal-to-metal contact on the workpiece. Do not attach the work clamp to the portion of the workpiece being cut away. (See Fig. 3-3 for proper connection.)

Air Supply

The air supply must provide 127 liters/minute (4.5 scfm) at a pressure greater than 4.1 bar (60 psi) for a minimum of a 35% duty cycle.

Figure 3-2 Linkboard Connections

MAX20 Instruction Manual 3-7

SETUP

The air supply must be clean, dry and free of oil or dirt. Air pressure greater than 4.1 bar (60 psi) within a range of

4.8 - 8.6 bar (70-125 psi) should be applied to the air filter unit located on the back panel of the unit. Pressure

must not exceed 8.6 bar (125 psi). The air pressure regulator is preset at the factory and regulated to 4.1 bar (60 psi) pressure when the gas flow is on.* To adjust the pressure regulator, refer to the adjustment procedure in

Troubleshooting.

*The pressure is set to 4.5 bar (65 ± 2 psi) when a 7.5 meter (25-foot) lead is used.

Figure 3-4 Air Supply

Figure 3-3 Proper Work Clamp Connection

3-8 MAX20 Instruction Manual

SETUP

MAX20 Instruction Manual 4-1

Section 4

OPERATION